Removal And Installation: Camshafts: Removing

WARNING: This page is about a different car, the 2013 Volkswagen Beetle and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

The sealing surfaces of the cylinder head cover and the cylinder head must not be reworked.

The camshaft bearings are integrated in the cylinder head and cylinder head cover. The tension must be released from the camshaft timing chain before removing the cylinder head cover.

If the cylinder head cover was removed, the sealing cap must be replaced.

All cable ties which are opened or cut off when removing, must be replaced in the same position when installing.

CAUTION:

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the vacuum pump. Refer to Removing .

-- Remove the noise insulation. Refer to Removal and Installation .

-- Remove the right front wheel.

-- Remove the right front wheel housing liner. Refer to Removal and Installation .

-- Remove the bolts -arrows-.

Fig 1: Locating Air Guide Pipe And Bolts

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-- Remove the charge air pipe by lifting the clamps -1 and 2-.

-- Disconnect the camshaft adjustment valve 1 connector -1-.

Fig 2: Locating Camshaft Adjustment Valve And Bolts

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-- Remove the bolts -arrows- and remove camshaft adjustment valve 1.

-- Remove the upper timing chain cover. Refer to Removing .

CAUTION: The control valve has left hand threads.

-- Remove the control valve in the -direction of the arrow- using the assembly toolT10352.

Fig 3: Identifying Assembly Tool T10352 To Remove Control Valve

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-- Remove the bolts -arrows- and remove the bearing bracket.

Fig 4: Locating Bearing Bracket Bolts

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-- Rotate the vibration damper to the Top Dead Center (TDC) position -arrow- using the counter hold tool T10355:

Fig 5: Identifying Vibration Damper "TDC" Position With Special Tool T10355

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The notch on the vibration damper must line up with the arrow mark on the lower timing chain cover.

-- Carefully mark the drive chain/chain sprockets -arrows- with a waterproof marker. These marks are necessary for reinstallation.

Fig 6: Identifying Drive Chain/Chain Sprocket Markings And Turning Intake Camshaft Using Wrench

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-- Remove the plug -arrow-.

Fig 7: Identifying Plug

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-- Lift the chain tensioner locking wedge by inserting a scribe or a suitable screwdriver into the hole in the chain tensioner in the -direction of arrow 1-.

Fig 8: Identifying Chain Tensioner Locking Wedge, Screwdriver, Crankshaft And Securing Pin T40011

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-- Rotate the crankshaft opposite engine rotation direction in the -direction of arrow 2- and secure it with a locking pin T40011.

NOTE: The intake camshaft switches in engine rotation direction.

-- Remove the camshaft timing chain guide pin -1- and guide the tensioning rail -2- downward.

Fig 9: Identifying Guide Tensioning Rail, Upper Guide Rai And Bolt

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-- Remove the camshaft timing chain guide rail -3- by unlocking the latch with a screwdriver and pushing the guide rail forward.

NOTE: When the lower timing chain cover is installed, the loose chain on the crankshaft cannot jump off.

-- Remove the camshaft timing chain from the chain sprockets.

CAUTION: Danger of damaging the valves, piston head and lower timing chain cover.

If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be rotated further.
Panels are installed on the lower timing chain cover to prevent the chain from falling down. The panels can bend if the crankshaft is rotated when the chain is loose.

-- Remove the ignition coils with output stages, refer to IGNITION COILS WITH POWER OUTPUT STAGES , and lay the wiring harness to the side.

Fig 10: Crankcase Ventilation Tightening Sequence